Unit IG2: Risk assessment

Declaration: By submitting this assessment (Parts 1 – 4) for marking I declare that it is entirely my own work. I understand that falsely claiming that
the work is my own is malpractice and can lead to NEBOSH imposing severe penalties (see the NEBOSH Malpractice Policy for further information).

Important note: You must refer to the document ‘Unit IG2: risk assessment – Guidance and information for learners and Learning Partners’ while
completing all parts of this assessment. Your Learning Partner should provide you with a copy, but it can also be downloaded from the relevant
resources section for this qualification on the NEBOSH website.

Part 1: Background

You should aim to complete this section in 150 - 200 words.

Topic Comments
Name of organisation* Cochin Shipyard Limited
Site location* Kerala, India
Number of workers 185
Cochin Shipyard was incorporated in the year 1972 as a fully owned Government of India company. In the
last three decades the company has emerged as a forerunner in the Indian Shipbuilding & Ship repair
industry. This yard can build and repair the largest vessels in India.

Cochin Shipyard Limited became one of the largest private ship building companies in India with a capacity
to manufacture vessels up to 20 tonnes in weight.

The process includes preparation of plates and sections as per design provided by clients, fabrication of sub-
assemblies in the machine shop. Then parts of the ships are fabricated as sub-units in hull shop. Sub-units
are finally erected and built into Ships in fabrication yard. Upon erection, the interiors of the ship are fabricated
General description of the organisation
inside the ship in the assembly shop. Finally, coating and painting is done. Then after finishing, the ships are
launched into backwater where trails and tests are conducted before commissioning. And finally, the ships
are handed over to the respective clients.

Cochin Shipyard Limited has many national and international clients including Indian Navy, Rolls Royce
Marine (Norway), GTT (France), Vard Group (Norway), etc.,

The company operates in single shift of 09 hours from 10:00 hrs to 19:00 hrs with an hour break from 14:00
hrs to 15:00 hrs. The company operates from Sunday to Thursday and having Friday and Saturday as week-
offs.

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 Some controls were already being implemented at the worksite like proper safety signages were displayed, regular
toolbox talks (TBTs) were being conducted, etc., which are mentioned in column 3 of part 2.

I have recommended the additional control measures based on site visits, information received from workers, ILO
C155, and other documents reviewed during the risk assessment. All the recommendations are arranged as per
hierarchy of risk control (ILO OSH 2001 clause 3.10.1.1) and are written in column 4 of the Risk Assessment sheet
(part 2).

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 Hazard Who might be harmed and What are you already doing? What further controls/actions are Timescales for Responsible
category and how? required? further actions person’s job
hazard to be completed title
(within …)

● Conduct noise survey for operator 06 months Medical Officer

and helpers using simple noise
meter periodically to detect early
symptoms of hearing impairment.

● Provide job rotation to the helpers 03 months Sectional head

and operator exposed to loud
noise to reduce risk of exposure to
loud noise.

● Provide frequent breaks to the 01 week Sectional head

workers and operator if job
rotation is not possible due to
competency requirement.

● Provide healthy ear defenders and 01 week Supervisor

ensure their healthiness.
Vibration Grinders ● TBT was provided to the ● Avoid working with damaged 01 week Floor Manager
grinders at the start of handle of grinding machine for
High vibration Grinding operation is done each shift and were prolonged duration without
generated due for edge preparation before documented in TBT appropriate control measures.
to damaged welding, and to remove register.
handles of the excess slag after welding. ● Repair the handle of grinding 02 weeks Maintenance
handheld This is a routine process. ● Hand gloves were machine to reduce risk of Engineer
portable electric provided to all grinders exposure to high vibration to the
grinding The Grinders who perform and were worn by the grinders.
machine this activity were exposed to grinders.
hand-arm vibration for the ● Provide new grinding machine 01 week Maintenance
entire shift. ● Only experienced grinders with low vibration if repair is not Engineer
were employed by the possible.
This exposure may lead to company.
various health issues like ● Provide anti-vibration handles to 01 week Maintenance
vibration white finger, loss of the grinding machine to reduce Engineer
sensation, pain, numbness the risk of exposure to high
in the hands and arms, etc., vibration.

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 Hazard Who might be harmed and What are you already doing? What further controls/actions are Timescales for Responsible
category and how? required? further actions person’s job
hazard to be completed title
(within …)
Traveling (EOT) level, and operators travels and worn by the operator
Crane with the controller of EOT and workers. ● Repair the audio alert system to 02 weeks Maintenance
crane to shift the materials warn the workers and other Engineer
from one end to another. ● Audio alert system was people working in the vicinity at
The helpers move along with available to warn the the start of the movement of EOT
the load to guide its workers during crane.
movement.
● Replace the audio alert system if 01 week Maintenance
Damaged hoist rope may damage is beyond repair. Engineer
break, and load may fall
upon the operator and ● Conduct preventive maintenance 03 months Maintenance
helper. This may result into of the EOT crane to avoid any Engineer
multiple injuries of head, failures during operation.
foot, hand, and leg or even
death. ● Provide tagline to control the 01 week Fabrication
swing of the load. Manager

● Mark correct SWL on the EOT 01 week Supervisor

crane and ensure that all the loads
are within SWL.

● Develop and implement SSOW for 01 weeks Sectional Head

safe operation of EOT crane.

● Provide training in SSOW for safe 02 weeks HSE Manager

working with EOT crane to
operator and worker to reduce the
risk of injury to them.

● Provide TBT on working with EOT 01 week HSE Manager

crane at the start of each shift,
and document it.

● Inspect all the lifting gears at the 01 week Operator

start of each shift.

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 Hazard Who might be harmed and What are you already doing? What further controls/actions are Timescales for Responsible
category and how? required? further actions person’s job
hazard to be completed title
(within …)
● Develop and implement SSOW for 01 weeks Sectional Head
safe operation of shot blasting
machine.
● Provide training in SSOW to 02 weeks HSE Manager
operator on safe working of shot
blasting machine.

● Provide job rotation to operator 03 months Sectional Head

exposed to the contaminated
environment.

● Provide frequent breaks if job 01 week Sectional Head

rotation is not practical due to
competency requirement.

● Provide proper respiratory 01 week Supervisor

Working at Welders, grinders, painters,
height and workers working at the
scaffold.
Fall from height
due to damaged When ship reaches the
rails of the assembly shop, all the
scaffolding fixtures are installed onto
edge of the ship. This is a
routine activity. All of them
work on the scaffold for the
entire shift.
The welders, grinders,
painter, and other workers
working on the scaffold may
fall from the scaffold leading
to bruising, sprains/strains,
fractures, or more serious
protection equipment to operator
and workers in the vicinity.
● TBT for was provided at ● Stop working on damaged 01 week Floor Manager
the start of each shift and scaffold.
were documented in TBT
register. ● Replace the damaged rails of the 01 week Maintenance
scaffold to reduce to risk of fall Engineer
● Mandatory PPEs for work from height to the workers working
at height signage were at the scaffold.
displayed in the area.
● Develop and implement SSOW for 01 week Sectional Head
● Area was barricaded to safe working at height at
prevent unauthorised scaffoldings.
entry around the scaffold.
● Provide training in SSOW to all 02 weeks HSE Manager
the workers for safe working at
height to reduce the risk of fall
from height.

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 Hazard Who might be harmed and What are you already doing? What further controls/actions are Timescales for Responsible
category and how? required? further actions person’s job
hazard to be completed title
(within …)

● Provide competent supervisor to 02 weeks Fabrication

supervise the workers working Manager
inside the ship.

● Develop and implement 02 weeks Sectional Head

Emergency Rescue Procedures
(ERP) for the workers working
inside the ship.

● Provide training in Emergency 02 weeks HSE Manager

rescue to the supervisor and
emergency department.

● Provide emergency rescue 02 weeks HSE Manager

arrangements to rescue the
workers from the ship in case of
emergency.

● Provide escape breathing 01 weeks HSE Manager

Slip and Trip Workers, visitors, etc., in the
hull shop.
Obstructed
walkways Protruding angles and tools
were lying along the
walkway.
Workers travel from one end
to another several times for
shifting materials during the
shift. These obstructions
along the walkway may lead
● Signage was displayed for
housekeeping in that area.
● Safety shoes were
provided to the workers.
● Designated walkways
were provided and were
properly marked.
apparatus inside the ships to be
used by workers in case of
emergency.
● Avoid dumping heavy plates and 01 week Floor Manager
angles in the walkway.
● Provide designated place to keep 02 weeks Floor Manager
the plates and angles.
● Provide training and information to 01 week Supervisor
create awareness of trip hazards
and how to avoid them.
● Provide clear emergency exits – 01 week Fabrication
free from any obstruction to be Manager

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 Hazard Who might be harmed and What are you already doing? What further controls/actions are Timescales for Responsible
category and how? required? further actions person’s job
hazard to be completed title
(within …)
contact with the rotating ● Only experienced workers ● Install interlocks to trip the bench- 03 weeks Maintenance
abrasive wheels. were deployed onto the top grinder when guards are partly Engineer
bench-top grinder. or fully not at its place.
This may result into hand
injury to the operator like ● Conduct preventive maintenance 03 months Maintenance
sever cuts, bruises, loss of of bench-top grinder to reduce Engineer
finger, etc., damage to the guards of the
machine.

● Install transparent glass/plastic 01 week Maintenance

screen over the abrasive wheels Engineer
to reduce exposure to dust into
the eyes.

● Install local exhaust ventilation to 02 months Maintenance

reduce the dust exposure to the Engineer
operator.

● Develop and implement SSOW for 01 week Sectional head

safe working of bench-top grinder.

● Provide training in SSOW to the 02 weeks HSE Manager

operator on safe working with
bench-top grinding machine.

● Provide supervisor to supervise 01 week Fabrication

the operator working on bench-top Manager
grinding machine.

● Provide hand and eye protection 01 week Fabrication

to the operator. Manager

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 Hazard Who might be harmed and What are you already doing? What further controls/actions are Timescales for Responsible
category and how? required? further actions person’s job
hazard to be completed title
(within …)
● Display MSDS for the acetylene 01 week HSE Manager
gas near the storage area.

● Appoint trained and competent 01 months Sectional head

Electricity Welders, helpers, and
workers working in the
Damaged vicinity.
insulation of
cables of Workers may come in
welding contact with the live
machine in the conductor while shifting the
hull shop loads from one place to
another. Also, welders and
helpers may come in contact
with the live conductors
while moving from one end
of the job piece to another.
Also, these live conductors
may come in contact with
metallic plates which is also
a good conductor of
electricity, thus increasing
the risk of electric shock.
The contact with live
conductors may result into
minor to sever pain, difficulty
in breathing, electric burns,
cardiac arrest and in worst
case death.
● Safety shoes were
provided to workers.
● Signages were displayed
to wear mandatory PPEs.
● Spark proof sockets were
provided in welding
machines for connections.
operators to perform critical and
risky hot work to ensure safe
working.
● Stop working with cables having 01 week Floor Manager
damaged insulation.
● Replace the damaged cables of 02 weeks Maintenance
welding machine to reduce the Engineer
risk of contact with live conductor
to the workers.
● Provide underground wiring with 01 month Maintenance
spark proof sockets installed near Engineer
the work area to avoid undue
wires lying along the walkway.
● Provide spark proof connectors for 03 weeks Maintenance
the extension cables. Engineer
● Provide properly rated (e.g., 01 week Maintenance
30mA) Residual Current Devices Engineer
(RCDs) in the circuit to trip the
supply in case of any leakage of
current in the events of accidental
contact with live conductors.
● Ensure the effective working of 01 week Operator
these RCDs at the start of each
shift.

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 ● How the risk assessment findings will be communicated and who needs to know the information: 100 - 150 words
● Follow up on the risk assessment: 100 - 150 words.
Planned review date/period with reasoning
How the risk assessment findings will be
communicated AND who you need to tell
How you will follow up on the risk
assessment to check that the actions have
been carried out
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As per company policy, risk assessment must be reviewed at least every twelve months. Hence, I set the review
date on or before 30th September 2023. However, I will review the risk assessment before the 30th September
2023, if any of the below mentioned changes takes place:
● The company procures new equipment or technology or adopts a new working procedure.
● Any change in relevant standards or legislation occurs that affects Cochin Shipyard Limited.
● Significant change in number of workforce or shift pattern of the workforce
● Any accident or dangerous occurrence takes place within this period.
To communicate the findings of risk assessment, I will arrange a formal meeting with the Factory manager and
will ask him to go through the entire risk assessment and assign the actions mentioned in column 4 of part 2 in
the risk assessment to the respective responsible personnel. I will email the summary and findings of the risk
assessment to the Sectional head, Safety officer, Floor Manager, Fabrication manager, HSE Manager,
Maintenance engineer, and Supervisors. The findings of the risk assessment will be included in the next toolbox
talks, where I will suggest the workers on actions to be taken to resolve these findings. A summary of the risk
assessment will be displayed on noticeboard and made available on the company’s intranet, which are
accessible to all workers.
I will speak to the responsible person for each of the actions to find out to what extent the actions have been
implemented. For actions whose time scales are over a month, I will set calendar reminder of roughly 10 days
before the due date of completion of the action. In case, if the implementation of any action is taking more time
than the indicated timescale, I will enquire for the reasons behind the delay in the implementation of the action
and will communicate the same with the Factory manager for resolution. Any action that are very overdue (i.e.,
completion is more than 4 months late) will be communicated to the Operations Director via the Factory
manager.
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